266 SYSTEM DESIGN

and THW-2. However, these types of wire insulations do not always have low smoke and
flame characteristics. Care must be exercised when wire is selected from manufacturers’
catalogs to ensure the correct insulation type (low smoke). Wires with thin insulations,
such as THHW, THWN, and THHN, have been used in some installations, but the associ-
ated slick nylon outer jacket makes the wire more difficult to handle and secure during
and after installation and their smoke products are undesirable.
For purposes of current rating calculations, the wire types are broadly classified as un-
jacketed and jacketed. The thicknesses of the insulations including jackets (if used) for
various wire sizes and insulation types are shown in Table 5.15. Wire current ratings are
shown in Table 5.16 for various installation conditions and physical layouts as follows:

Table 5.16(a) Single copper wire in free air

Table 5.16(b) Alternate current ratings for single copper wire in free air (based on
NEC)
Table 5-16(c) Two bundled copper wires
Table 5.16(d).1 Single unjacketed copper wires with no separation in one or more
layers, 75°C

Table 5.14 Copper Conductor Strand Properties and Weights

Coarse Strand (ASTM B8-04 Class B) Fine Strandb (ASTM B-172 Class I)
______________________________________ _______________________________________
AWG Strand Weight with AWG Strand Weight with
or Diameter Insulation or Diameter Insulation
kcmil Strands (mils) (lb/ft)a kcmil Strands (mils) (lb/ft)a
18 7 15 — — — — —
16 7 19 — — — — —
14 7 24 0.022 — — — —
12 7 30 0.031 — — — —
10 7 38 0.045 — — — —
8 7 49 0.074 8 41 20.1 0.082
6 7 61 0.108 6 63 20.1 0.117
4 7 77 0.161 4 105 20.1 0.175
3 7 87 0.198 3 133 20.1 —
2 7 97 0.244 2 161 20.1 0.253
1 19 66 0.319 1 210 20.1 —
1/0 19 74 0.392 1/0 266 20.1 0.423
2/0 19 84 0.484 2/0 342 20.1 0.538
3/0 19 94 0.599 3/0 418 20.1 —
4/0 19 106 0.743 4/0 532 20.1 0.790
250 37 82 0.889 250 637 — —
350 37 97 1.217 350 882 20.1 1.302
500 37 116 1.703 500 1,225 20.1 1.831
750 61 111 2.540 750 1,862 20.1 2.752
1,000 61 128 3.343 1,000 2,527 20.1 —
1,250 91 117 4.310 1,250 3,059 20.1 —
1,500 91 128 5.110 1,500 3,724 20.1 —
2,000 127 126 6.910 2,000 4,921 20.1 —
a
Weight varies slightly with the type of insulation.
b
Variations exist between different types of fine-strand wire; the table above is based on wire designed for use in
telecommunications central offices.
 5.8 CIRCUIT DESIGN 267

Table 5.15 Insulated Wire Propertiesa

Insulation Thickness (Mils)b
Conductor
AWG or Diameter RHH, RHW,
kcmil (in.) Hookup THW RHW-2 Jacketed
18 0.046 15–30 — — —
16 0.058 15–30 — — —
14 0.073 15–30 30 45 60
12 0.092 15–30 30 45 60
10 0.116 15–30 30 45 60
8 0.146 — 45 60 90
6 0.184 — 60 60 90
4 0.232 — 60 60 90
3 0.260 — 60 60 90
2 0.292 — 60 60 90
1 0.332 — 80 80 125
1/0 0.372 — 80 80 125
2/0 0.418 — 80 80 125
3/0 0.470 — 80 80 125
4/0 0.528 — 80 80 125
250 0.575 — 95 95 160
350 0.681 — 95 95 160
500 0.813 — 95 95 160
750 0.998 — 110 110 175
1,000 1.152 — 110 110 175
1,250 1.289 — 125 125 220
1,500 1.412 — 125 125 220
2,000 1.632 — 125 125 220
a
Hookup wire 300–600 V rating, all other wire 600 V rating.
b
Outside diameter of insulated wire = Conductor diameter + 2 × Insulation thickness.

Table 5.16(d).2 Single jacketed copper wires with no separation in one or more
layers, 75°C
Table 5.16(d).3 Single unjacketed copper wires with no separation in one or more
layers, 90°C
Table 5.16(d).4 Single jacketed copper wires with no separation in one or more
layers, 90°C
Table 5.16(e).1 Rounded bundle of unjacketed copper wires, 75° C
Table 5.16(e).2 Rounded bundle of jacketed copper wires, 75° C
Table 5.16(e).3 Rounded bundle of unjacketed copper wires, 90° C
Table 5.16(e).4 Rounded bundle of jacketed copper wires, 90° C

The descriptions of the installation conditions, physical layouts, and current rating cal-
culations are provided in Section 5.8.1.6.
Rigid busbars are used where it is necessary to carry large currents over relatively long
distances and typically are found in systems or circuits exceeding approximately 800 to
1000-A capacity. In most applications, rigid busbars are uninsulated (bare), although they
usually are taped or covered with an insulating cover where subject to accidental contact.
Rigid copper busbar physical and electrical properties including current ratings are
268 SYSTEM DESIGN

Table 5.16(a) Calculated Current Ratings in Free Air for Unjacketed and Jacketed Single Copper
Wires at 75°C and 90°C with 30°C Ambient Temperature
Insulation Unjacketed Unjacketed Insulation Jacketed Jacketed
Thickness DC Current DC Current Thickness DC Current DC Current
AWG or Unjacketed Rating Rating Jacketed rating rating
kcmil (in.) 75°C (A) 90°C (A) (in.) 75°C (A) 90°C (A)
(1) (2) (3) (4) (5) (6) (7)
14 0.045 34 39 0.060 34 40
12 0.045 44 51 0.060 45 52
10 0.045 59 68 0.060 60 69
8 0.060 79 92 0.090 81 93
6 0.060 105 122 0.090 107 124
4 0.060 141 164 0.090 143 165
3 0.060 163 190 0.090 165 191
2 0.060 190 220 0.090 191 221
1 0.080 221 256 0.125 222 257
1/0 0.080 257 299 0.125 258 298
2/0 0.080 299 347 0.125 299 346
3/0 0.080 348 404 0.125 347 402
4/0 0.080 406 471 0.125 404 467
250 0.095 453 525 0.160 448 518
350 0.095 566 657 0.160 558 646
500 0.095 718 834 0.160 706 816
750 0.110 943 1,094 0.175 923 1,068
1,000 0.110 1,146 1,330 0.175 1,120 1,295
1,250 0.125 1,330 1,541 0.220 1,284 1,482
1,500 0.125 1,509 1,749 0.220 1,454 1,679
2,000 0.125 1,842 2,135 0.220 1,771 2,045

shown in Table 5.17 (single busbar) and Table 5.18 (parallel busbars). Table 5.18 consists
of:

Table 5-18(a) ¼ in. Parallel Busbars

Table 5-18(b) ⅜ in. Parallel Busbars
Table 5-18(c) ½ in. Parallel Busbars
Table 5-18(d) ¾ in. Parallel Busbars

Table 5.19 provides alternate ratings for some busbar configurations and is based on
ANSI/T1.311 [28]. Refer to table notes for additional details on using these tables. Table
5.19 does not cover as many combinations, and the current ratings generally are higher
than Tables 5.17 and 5.18, particularly for parallel bars. However, Table 5.19 values have
been used successfully in the telecommunications industry for many years. Also, Table
5.19 provides current ratings for the situations where the busbar is mounted in such a way
that its ability to dissipate heat is diminished, such as when the bars are spaced less than
their thickness, run with the long edge horizontal, or run in the vertical direction. When
there is doubt or any discrepancies in the current ratings in this book, the more conserva-
tive (lower) current ratings should be used.
Busbars used in electrical power applications generally are referred to as copper No.
110 busbars, also called electrolytic tough pitch (ETP) or ETP-110 or C11000 (copper
 5.8 CIRCUIT DESIGN 269

Table 5.16(b) DC Current Ratings in Free Air Calculated from the NEC [29] for Copper Wire at
75°C and 90°C
AWG or Skin Effect/Proximity NEC Free Air dc NEC Free Air DC
kcmil Effect Factor, FSPa Current Rating 75°C (A)b Current Rating 90°C (A)b
(1) (2) (3) (4)
14 1.00 30 35
12 1.00 35 40
10 1.00 50 55
8 1.00 70 80
6 1.00 95 105
4 1.00 125 140
3 1.00 145 165
2 1.00 170 190
1 1.00 195 220
1/0 1.00 230 260
2/0 1.00 265 300
3/0 1.00 310 350
4/0 1.00 360 405
250 1.00 405 455
350 1.00 505 570
500 1.01 626 707
750 1.02 801 903
1,000 1.03 963 1,087
1,250 1.05 1,118 1,260
1,500 1.07 1,257 1,418
2,000 1.11 1,537 1,732
a
From [30].
b
The dc current ratings in columns (3) and (4) are ac ampacities from Table 310.16 of [29] multiplied by the
factors in column (2).

that has been refined electrolytically). The busbar is 99.90% pure copper by weight and
has 101% IACS (International Annealed Copper Standard) electrical conductivity and
10.371 -CM/ft resistivity at 20°C.

5.8.1.4 Parallel Conductors It is frequently necessary to use parallel conductors

to reduce voltage drop, increase current rating, or both (Fig. 5.34). Where wire conductors
are connected in parallel, their length must be the same to ensure current sharing. The
conductors must be the same size and type and same material, and they must be terminat-
ed using the same materials and methods. Where parallel conductors are to be used, they
must be used on both sides of the circuit (feed and return)—in other words, if the feed
uses parallel wires, the return also must use parallel wires.
The resistance of parallel conductors equals the resistance of one conductor divided by
the number of conductors in parallel:

RCond
RP =  (5.23)
NCond

where RP = resistance of parallel conductors

RCond = resistance of one of the conductors
NCond = number of conductors connected in parallel
270 SYSTEM DESIGN

Table 5.16(c) Calculated Current Ratings for Two Bundled Unjacketed and Jacketed Copper
Wires at 75°C and 90°C
Insulation Unjacketed Unjacketed Insulation Jacketed Jacketed
Thickness DC Current DC Current Thickness DC Current DC Current
AWG or Unjacketed Rating Rating Jacketed Rating Rating
kcmil (in.) 75°C (A) 90°C (A) (in.) 75°C (A) 90°C (A)
(1) (2) (3) (4) (5) (6) (7)
14 0.045 29 34 0.060 30 35
12 0.045 38 45 0.060 39 46
10 0.045 51 59 0.060 52 61
8 0.060 69 80 0.090 71 83
6 0.060 92 107 0.090 94 110
4 0.060 123 143 0.090 126 146
3 0.060 142 165 0.090 145 168
2 0.060 165 192 0.090 168 195
1 0.080 193 225 0.125 197 228
1/0 0.080 225 262 0.125 228 264
2/0 0.080 261 303 0.125 264 306
3/0 0.080 304 353 0.125 306 355
4/0 0.080 353 411 0.125 355 412
250 0.095 395 459 0.160 397 460
350 0.095 494 574 0.160 494 572
500 0.095 625 726 0.160 622 721
750 0.110 820 953 0.175 814 943
1,000 0.110 995 1,156 0.175 985 1,141
1,250 0.125 1,156 1,343 0.220 1,135 1,314
1,500 0.125 1,310 1,521 0.220 1,284 1,486
2,000 0.125 1,595 1,852 0.220 1,560 1,805

The circular mil area of parallel conductors equals the circular mil area of one of the con-
ductors times the number of conductors in parallel:

CMP = CMCondNCond (5.24)

where CMP = circular mil area of the parallel conductors

CMCond = circular mil area of one of the conductors
NCond = number of conductors connected in parallel

It is not normal practice to use parallel conductors in sizes smaller than 1/0 AWG, but
there are many exceptions to this practice, particularly in smaller systems. However, there
is no reason to parallel conductors smaller than 2 AWG even in small systems. Parallel
conductors smaller than 1/0 AWG are not allowed in installations covered by the Nation-
al Electrical Code.20

5.8.1.5 Voltage Drop Calculations The dc voltage drop calculations are some-
what simpler than ac voltage drop calculations because with dc there is no skin effect or
reactance due to operating frequency. Two methods are used:

앫 The first method is based on a simple factor (voltage drop factor, sometimes called

20
2005 NEC, Article 310.4. [29].
 Table 5.16(d).1 Current Ratings for Unjacketed Single (1/C) Copper Wires at 75°C with No Separation in One or More Layers—30°C Ambient Temperaturea
Conductor dc Resistance Free Air Current Rating Unjacketed 75°C (A)
AWG Cross Wire 75°Cc DC Current
Apparent (Calculated) Wire Mass Fill Depth
or Section Diameterb ( per Ratingd
kcmil (CM) (in.) 1000 ft) 75°C (A) 1 in. 1.5 in. 2 in. 2.5 in. 3 in. 3.5 in. 4 in.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
14 4,110 0.163 3.13767 34 6.5 5.1 4.2 3.6 3.2 2.8 2.6
12 6,530 0.182 1.98232 44 9.1 7.1 5.9 5.1 4.4 4.0 3.6
10 10,380 0.206 1.24047 59 13 10 8.4 7.2 6.4 5.7 5.2
8 16,510 0.266 0.77834 79 21 17 14 12 10 9.3 8.4
6 26,240 0.304 0.49011 105 31 24 20 17 15 13 12
4 41,740 0.352 0.30769 141 45 35 29 25 22 20 18
3 52,620 0.380 0.24445 163 54 42 35 30 26 24 21
2 66,360 0.412 0.19337 190 66 51 43 37 32 29 26
1 83,690 0.492 0.15445 221 88 69 57 49 43 39 35
1/0 105,600 0.532 0.12162 257 108 84 69 60 52 47 43
2/0 133,100 0.578 0.09668 299 131 102 85 73 64 57 52
3/0 167,800 0.630 0.07662 348 161 125 104 89 78 70 63
4/0 211,600 0.688 0.06081 406 197 153 127 109 96 86 78
250 250,000 0.765 0.05144 453 238 185 153 132 116 104 94
350 350,000 0.871 0.03673 566 321 250 207 178 156 140 127
500 500,000 1.003 0.02578 718 442 343 284 244 215 192 174
750 750,000 1.218 0.01715 943 657 511 423 363 320 286 259
1,000 1,000,000 1.372 0.01289 1,146 854 664 550 472 415 372 337
1,250 1,250,000 1.539 0.01030 1,330 1,072 833 690 593 521 467 423
1,500 1,500,000 1.662 0.00857 1,509 1,269 986 817 702 617 552 501
2,000 2,000,000 1.882 0.00643 1,842 1,659 1,289 1,068 917 807 722 654
a
No diversity. Free air current rating is shown for reference.
b
From NFPA 70-2005 (NEC®) Table 8 and Table 310.13 [28, nec]
c
dc resistance from ASTM B8-04 [27, ASTM B8], adjusted to 75°C
d
From Table 5.16(a)

271
 Table 5.16(d).2 Current Ratings for Jacketed Single Copper Wires (1/C) at 75°C with No Separation in One or More Layers—30°C Ambient Temperaturea

272
Conductor DC Resistance Free Air DC Current Rating Jacketed 75°C (A)
AWG Cross Wire 75°Cc DC Current
Apparent (Calculated) Wire Mass Fill Depth
or Section Diameterb ( per Ratingd
kcmil (CM) (in.) 1000 ft) 75°C (A) 1 in. 1.5 in. 2 in. 2.5 in. 3 in. 3.5 in. 4 in.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
14 4,110 0.193 3.13767 34 7.7 6.0 5.0 4.3 3.7 3.4 3.0
12 6,530 0.212 1.98232 45 11 8.3 6.8 5.9 5.2 4.6 4.2
10 10,380 0.236 1.24047 60 15 12 9.6 8.3 7.3 6.5 5.9
8 16,510 0.326 0.77834 81 26 20 17 14 13 11 10
6 26,240 0.364 0.49011 107 37 29 24 20 18 16 15
4 41,740 0.412 0.30769 143 53 41 34 29 26 23 21
3 52,620 0.440 0.24445 165 63 49 41 35 31 27 25
2 66,360 0.472 0.19337 191 76 59 49 42 37 33 30
1 83,690 0.582 0.15445 222 105 81 67 58 51 46 41
1/0 105,600 0.622 0.12162 258 126 98 81 70 61 55 50
2/0 133,100 0.668 0.09668 299 152 118 98 84 74 66 60
3/0 167,800 0.720 0.07662 347 184 143 118 102 89 80 73
4/0 211,600 0.778 0.06081 404 223 173 144 123 108 97 88
250 250,000 0.895 0.05144 448 279 217 180 154 136 121 110
350 350,000 1.001 0.03673 558 369 287 238 204 180 161 146
500 500,000 1.133 0.02578 706 499 388 321 276 243 217 197
750 750,000 1.348 0.01715 923 728 565 468 402 354 317 287
1,000 1,000,000 1.502 0.01289 1,120 935 727 602 517 455 407 369
1,250 1,250,000 1.729 0.01030 1,284 1,204 936 775 666 586 524 475
1,500 1,500,000 1.852 0.00857 1,454 1,414 1,099 910 782 688 615 558
2,000 2,000,000 2.072 0.00643 1,771 1,826e 1,419 1,175 1,010 888 795 720
a
No diversity. Free air current rating is shown for reference.
b
From NFPA 70-2005 (NEC) Table 8 and Table 310.13 [28].
c
dc resistance from ASTM B8-04 [27, ASTM B8], adjusted to 75°C.
d
From Table 5.16(a).
e
Use free air current rating.
 Table 5.16(d).3 Current Ratings for Unjacketed Single Copper Wires (1/C) at 90°C with No Separation in One or More Layers—30°C Ambient Temperaturea
Conductor DC Resistance Free Air DC Current Rating Unjacketed 90°C (A)
AWG Cross Wire 90°Cc DC Current
Apparent (Calculated) Wire Mass Fill Depth
or Section Diameterb ( per Ratingd
kcmil (CM) (in.) 1000 ft) 90°C (A) 1 in. 1.5 in. 2 in. 2.5 in. 3 in. 3.5 in. 4 in.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
14 4,110 0.163 3.28976 39 7.5 5.8 4.8 4.1 3.6 3.2 2.9
12 6,530 0.182 2.07841 51 11 8.2 6.7 5.8 5.1 4.5 4.1
10 10,380 0.206 1.30060 68 15 12 9.7 8.3 7.3 6.5 5.9
8 16,510 0.266 0.81606 92 25 19 16 14 12 11 9.6
6 26,240 0.304 0.51387 122 35 27 23 20 17 15 14
4 41,740 0.352 0.32260 164 52 40 33 28 25 22 20
3 52,620 0.380 0.25630 190 63 49 40 34 30 27 24
2 66,360 0.412 0.20274 220 77 59 49 42 37 33 30
1 83,690 0.492 0.16194 256 102 79 65 56 49 44 40
1/0 105,600 0.532 0.12751 299 125 96 80 68 60 54 49
2/0 133,100 0.578 0.10137 347 152 118 97 83 73 65 59
3/0 167,800 0.630 0.08033 404 186 144 119 102 90 80 72
4/0 211,600 0.688 0.06376 471 228 176 146 125 110 98 89
250 250,000 0.765 0.05394 525 276 213 176 151 133 119 107
350 350,000 0.871 0.03851 657 371 287 238 204 179 160 145
500 500,000 1.003 0.02703 834 510 395 326 280 246 220 199
750 750,000 1.218 0.01798 1,094 760 588 486 417 366 327 296
1,000 1,000,000 1.372 0.01352 1,330 987 764 631 541 475 425 385
1,250 1,250,000 1.539 0.01080 1,541 1,239 959 792 679 597 533 483
1,500 1,500,000 1.662 0.00899 1,749 1,466 1,135 938 804 706 631 571
2,000 2,000,000 1.882 0.00675 2,135 1,916 1,484 1,226 1,051 923 825 747
a
No diversity. Free air current rating is shown for reference.
b
From NFPA 70-2005 (NEC) Table 8 and Table 310.13 [29].
c
dc resistance from ASTM B8-04 [27], adjusted to 90°C.
d
From Table 5.16(a).

273
 Table 5.16(d).4 Current Ratings for Jacketed Single Copper Wires (1/C) at 90°C with No Separation in One or More Layers—30°C Ambient Temperaturea

274
Conductor DC Resistance Free Air DC Current Rating Jacketed 90°C (A)
AWG Cross Wire 90°Cc DC Current
Apparent (Calculated) Wire Mass Fill Depth
or Section Diameterb ( per Ratingd
kcmil (CM) (in.) 1000 ft) 90°C (A) 1 in. 1.5 in. 2 in. 2.5 in. 3 in. 3.5 in. 4 in.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
14 4,110 0.193 3.28976 40 8.9 6.9 5.7 4.9 4.3 3.8 3.5
12 6,530 0.212 2.07841 52 12 9.5 7.9 6.7 5.9 5.3 4.8
10 10,380 0.236 1.30060 69 17 13 11 9.5 8.3 7.5 6.7
8 16,510 0.326 0.81606 93 30 23 19 17 15 13 12
6 26,240 0.364 0.51387 124 42 33 27 23 20 18 17
4 41,740 0.412 0.32260 165 61 47 39 33 29 26 24
3 52,620 0.440 0.25630 191 73 56 47 40 35 31 28
2 66,360 0.472 0.20274 221 88 68 56 48 42 38 34
1 83,690 0.582 0.16194 257 121 94 77 66 58 52 47
1/0 105,600 0.622 0.12751 298 146 113 93 80 70 63 57
2/0 133,100 0.668 0.10137 346 175 136 112 96 85 76 68
3/0 167,800 0.720 0.08033 402 212 165 136 117 102 91 83
4/0 211,600 0.778 0.06376 467 258 200 165 141 124 111 100
250 250,000 0.895 0.05394 518 322 250 206 177 155 139 126
350 350,000 1.001 0.03851 646 427 330 273 234 206 184 166
500 500,000 1.133 0.02703 816 576 446 369 316 278 248 225
750 750,000 1.348 0.01798 1,068 841 651 538 461 405 362 328
1,000 1,000,000 1.502 0.01352 1,295 1,081 837 691 593 521 465 421
1,250 1,250,000 1.729 0.01080 1,482 1,392 1,078 890 763 670 599 542
1,500 1,500,000 1.852 0.00899 1,679 1,634 1,265 1,045 896 787 703 637
2,000 2,000,000 2.072 0.00675 2,045 2,110e 1,633 1,350 1,157 1,016 908 822
a
No diversity. Free air current rating is shown for reference.
b
From NFPA 70-2005 (NEC) Table 8 and Table 310.13 [29].
c
dc resistance from ASTM B8-04 [27], adjusted to 90°C.
d
From Table 5.16(a).
e
Use free air current rating.
 5.8 CIRCUIT DESIGN 275

Table 5.16(e).1 Calculated Current Ratings for Rounded Bundles of 14–4/0 AWG Unjacketed
Copper Wiresa
Insulation DC Current Rating Unjacketed 75°C (A)
Thickness
Number of Unjacketed Wires in Bundle
AWG Unjacketed
or kcmil (in.) 4 6 8 10 12 14 16
(1) (2) (3) (4) (5) (6) (7) (8) (9)
14 0.045 22 19 18 16 15 14 14
12 0.045 29 25 23 21 20 19 18
10 0.045 38 33 30 28 26 25 23
8 0.060 52 45 41 38 35 33 32
6 0.060 68 59 53 49 46 43 41
4 0.060 90 78 70 65 60 57 54
3 0.060 103 89 80 7 69 65 62
2 0.060 119 102 92 85 79 75 71
1 0.080 139 120 108 99 93 88 83
1/0 0.080 160 138 124 114 107 101 96
2/0 0.080 184 158 142 131 122 115 109
3/0 0.080 211 182 163 150 140 132 125
4/0 0.080 243 209 187 172 160 151 143
a
Maximum temperature 75°C with ambient temperature 30°C. Applies only to bundles in which all wires are the
same size.

Table 5.16(e).2 Calculated Current Ratings for Rounded Bundles of 14–4/0 AWG Jacketed
Copper Wiresa
Insulation DC Current Rating Jacketed 75°C (A)
Thickness
Number of Jacketed Wires in Bundle
AWG Jacketed
or kcmil (in.) 4 6 8 10 12 14 16
(1) (2) (3) (4) (5) (6) (7) (8) (9)
14 0.060 24 20 18 17 16 15 14
12 0.060 31 26 24 22 21 20 19
10 0.060 40 35 31 29 27 26 24
8 0.090 55 48 43 40 37 35 33
6 0.090 72 62 56 52 48 46 43
4 0.090 94 81 73 67 63 59 56
3 0.090 107 93 83 77 72 68 64
2 0.090 123 106 96 88 82 77 74
1 0.125 146 126 113 104 97 91 87
1/0 0.125 167 144 129 119 111 104 99
2/0 0.125 191 164 147 135 126 119 113
3/0 0.125 219 188 168 155 144 136 129
4/0 0.125 251 215 193 177 164 155 147
a
Maximum temperature 75°C with ambient temperature 30°C. Applies only to bundles in which all wires are the
same size.
276 SYSTEM DESIGN

Table 5.16(e).3 Calculated Current Ratings for Rounded Bundles of 14–4/0 AWG Unjacketed
Copper Wiresa
Insulation DC Current Rating Unjacketed 90°C (A)
Thickness
Number of Unjacketed Wires in Bundle
AWG Unjacketed
or kcmil (in.) 4 6 8 10 12 14 16
(1) (2) (3) (4) (5) (6) (7) (8) (9)
14 0.045 26 23 20 19 18 17 16
12 0.045 34 29 27 24 23 22 21
10 0.045 44 38 35 32 30 28 27
8 0.060 60 52 47 43 41 38 37
6 0.060 79 68 62 57 53 50 48
4 0.060 104 90 81 75 70 66 63
3 0.060 119 103 93 85 80 75 72
2 0.060 137 118 106 98 91 86 82
1 0.080 161 139 125 114 107 101 96
1/0 0.080 185 159 143 131 123 116 110
2/0 0.080 212 183 164 150 140 132 125
3/0 0.080 244 209 188 172 161 151 143
4/0 0.080 280 240 215 197 184 173 164
a
Maximum temperature 90°C with ambient temperature 30°C. Applies only to bundles in which all wires are the
same size.

Table 5.16(e).4 Calculated Current Ratings for Rounded Bundles of 14–4/0 AWG Jacketed
Copper Wiresa
Insulation DC Current Rating Jacketed 90°C (A)
Thickness
Number of Jacketed Wires in Bundle
AWG Jacketed
or kcmil (in.) 4 6 8 10 12 14 16
(1) (2) (3) (4) (5) (6) (7) (8) (9)
14 0.060 27 24 21 20 19 18 17
12 0.060 35 31 28 26 24 23 22
10 0.060 46 40 36 33 31 29 28
8 0.090 64 55 50 46 43 41 39
6 0.090 83 72 65 60 56 53 50
4 0.090 109 94 84 78 72 68 65
3 0.090 124 107 96 89 83 78 74
2 0.090 142 123 110 101 95 89 85
1 0.125 168 145 130 119 111 105 99
1/0 0.125 193 166 149 136 127 120 114
2/0 0.125 220 189 69 155 145 136 129
3/0 0.125 252 216 194 178 165 156 148
4/0 0.125 289 247 221 203 189 177 168
a
Maximum temperature 90°C with ambient temperature 30°C. Applies only to bundles in which all wires are the
same size.
 Table 5.17 Rigid Copper Bus Properties—1 Bara,b
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
1– 1
4
–
2 0.125 159 0.483 68.39 81.82 241
1– –3
4 4 0.188 239 0.726 45.52 54.47 322
1–
4 1 0.250 318 0.966 34.19 40.91 404
1–
4 11–2 0.375 477 1.450 22.76 27.23 568
1–
4 2 0.500 637 1.930 17.15 20.52 724
1–
4 21–2 0.625 796 2.410 13.72 16.41 875
1–
4 3 0.750 955 2.900 11.43 13.68 1,029
1–
4 31–2 0.875 1,114 3.380 9.77 11.69 1,206
1–
4 4 1.000 1,273 3.860 8.55 10.23 1,323
1–
4 5 1.250 1,592 4.830 6.84 8.18 1,616
1–
4 6 1.500 1,910 5.800 5.71 6.83 1,901
1–
4 8 2.000 2,546 7.730 4.27 5.11 2,495
1–
4 10 2.500 3,183 9.660 3.42 4.09 3,043
1–
4 12 3.000 3,820 11.600 2.85 3.41 3,605
3– –3
8 4 0.281 358 1.090 30.45 36.44 419
3–
8 1 0.375 477 1.450 22.76 27.23 518
3–
8 11–2 0.563 716 2.170 15.17 18.16 728
3–
8 2 0.750 955 2.900 11.43 13.68 915
3–
8 21–2 0.938 1,194 3.620 9.11 10.91 1,111
3–
8 3 1.125 1,432 4.350 7.64 9.14 1,287
3–
8 31–2 1.313 1,671 5.060 6.53 7.81 1,466
3–
8 4 1.500 1,910 5.800 5.71 6.83 1,643
3–
8 5 1.875 2,387 7.260 4.55 5.45 2,004
3–
8 6 2.250 2,865 8.690 3.80 4.55 2,367
3–
8 8 3.000 3,820 11.600 2.85 3.41 3,056
3–
8 10 3.750 4,775 14.500 2.28 2.72 3,759
3–
8 12 4.500 5,730 17.400 1.90 2.28 4,409
1–
2 1 0.500 637 1.930 17.15 20.52 632
1–
2 11–2 0.750 955 2.900 11.43 13.68 863
1–
2 2 1.000 1,273 3.860 8.55 10.23 1,058
1–
2 21–2 1.250 1,592 4.830 6.84 8.18 1,292
1–
2 3 1.500 1,910 5.800 5.71 6.83 1,534
1–
2 31–2 1.750 2,228 6.760 4.88 5.84 1,726
1–
2 4 2.000 2,546 7.730 4.27 5.11 1,908
1–
2 5 2.500 3,183 9.660 3.42 4.09 2,355
1–
2 6 3.000 3,820 11.600 2.85 3.41 2,799
1–
2 8 4.000 5,093 15.500 2.14 2.56 3,575
1–
2 10 5.000 6,366 19.300 1.71 2.05 4,365
1–
2 12 6.000 7,639 23.200 1.42 1.70 5,178
–3 4 3.000 3,820 11.600 2.85 3.41 2,443
4
–3 5 3.750 4,775 14.500 2.28 2.72 2,920
4
–3 6 4.500 5,730 17.400 1.90 2.28 3,452
4
–3 8 6.000 7,639 23.200 1.42 1.70 4,427
4
–3 10 7.500 9,549 29.000 1.14 1.37 5,428
4
–3 12 9.000 11,459 34.800 0.95 1.14 6,426
4
a
1 /ft = 1 × 10–6 /ft. For example, 68.39 /ft = 68.39 × 10–6 /ft.
b
Current ratings apply when the busbar is oriented with its long edge vertical, and bar spacing bar thickness,
and busbar is run in the horizontal plane. Current ratings based on 30°C rise above 40°C ambient temperature.
Source: Data from www.copper.org (Copper Development Association, Inc.).
277
278 SYSTEM DESIGN

Table 5.18(a) Rigid Copper Busbar Properties—1–4-in. Parallel Bars as Indicateda,b

DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) /ft /ft (A)
2 Parallel Bars
1– 1
4
–
2 0.250 318 0.966 34.195 40.910 434
1– –3
4 4 0.375 477 1.452 22.760 27.235 579
1–
4 1 0.500 637 1.932 17.095 20.455 727
1–
4 11–2 0.750 955 2.900 11.380 13.615 1,023
1–
4 2 1.000 1,273 3.860 8.575 10.260 1,303
1–
4 21–2 1.250 1,592 4.820 6.860 8.205 1,575
1–
4 3 1.500 1,910 5.800 5.715 6.840 1,852
1–
4 31–2 1.750 2,228 6.760 4.885 5.845 2,171
1–
4 4 2.000 2,546 7.720 4.275 5.115 2,381
1–
4 5 2.500 3,183 9.660 3.420 4.090 2,908
1–
4 6 3.000 3,820 11.600 2.855 3.415 3,422
1–
4 8 4.000 5,093 15.460 2.135 2.555 4,492
1–
4 10 5.000 6,366 19.320 1.710 2.045 5,477
1–
4 12 6.000 7,639 23.200 1.425 1.705 6,490
3 Parallel Bars
1– 1
4
–
2 0.375 477 1.449 22.797 27.273 603
1– –3
4 4 0.563 716 2.178 15.173 18.157 804
1–
4 1 0.750 955 2.898 11.397 13.637 1,010
1–
4 11–2 1.125 1,432 4.350 7.587 9.077 1,421
1–
4 2 1.500 1,910 5.790 5.717 6.840 1,810
1–
4 21–2 1.875 2,387 7.230 4.573 5.470 2,188
1–
4 3 2.250 2,865 8.700 3.810 4.560 2,572
1–
4 31–2 2.625 3,342 10.140 3.257 3.897 3,015
1–
4 4 3.000 3,820 11.580 2.850 3.410 3,307
1–
4 5 3.750 4,775 14.490 2.280 2.727 4,039
1–
4 6 4.500 5,730 17.400 1.903 2.277 4,752
1–
4 8 6.000 7,639 23.190 1.423 1.703 6,238
1–
4 10 7.500 9,549 28.980 1.140 1.363 7,607
1–
4 12 9.000 11,459 34.800 0.950 1.137 9,013
4 Parallel Bars
1– 1
4
–
2 0.500 637 1.932 17.098 20.455 772
1– –3
4 4 0.750 955 2.904 11.380 13.618 1,029
1–
4 1 1.000 1,273 3.864 8.548 10.228 1,293
1–
4 11–2 1.500 1,910 5.800 5.690 6.808 1,819
1–
4 2 2.000 2,546 7.720 4.288 5.130 2,317
1–
4 21–2 2.500 3,183 9.640 3.430 4.103 2,800
1–
4 3 3.000 3,820 11.600 2.858 3.420 3,292
1–
4 31–2 3.500 4,456 13.520 2.443 2.923 3,860
1–
4 4 4.000 5,093 15.440 2.138 2.558 4,233
1–
4 5 5.000 6,366 19.320 1.710 2.045 5,170
1–
4 6 6.000 7,639 23.200 1.428 1.708 6,083
1–
4 8 8.000 10,186 30.920 1.068 1.278 7,985
1–
4 10 10.000 12,732 38.640 0.855 1.023 9,737
1–
4 12 12.000 15,279 46.400 0.713 0.853 11,537
 5.8 CIRCUIT DESIGN 279

Table 5.18(a) Rigid Copper Busbar Properties—1–4-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) /ft /ft (A)
5 Parallel Bars
1– 1
4
–
2 0.625 796 2.415 13.678 16.364 941
1– –3
4 4 0.938 1,194 3.630 9.104 10.894 1,254
1–
4 1 1.250 1,592 4.830 6.838 8.182 1,576
1–
4 11–2 1.875 2,387 7.250 4.552 5.446 2,217
1–
4 2 2.500 3,183 9.650 3.430 4.104 2,824
1–
4 21–2 3.125 3,979 12.050 2.744 3.282 3,413
1–
4 3 3.750 4,775 14.500 2.286 2.736 4,012
1–
4 31–2 4.375 5,570 16.900 1.954 2.338 4,704
1–
4 4 5.000 6,366 19.300 1.710 2.046 5,159
1–
4 5 6.250 7,958 24.150 1.368 1.636 6,301
1–
4 6 7.500 9,549 29.000 1.142 1.366 7,414
1–
4 8 10.000 12,732 38.650 0.854 1.022 9,732
1–
4 10 12.500 15,915 48.300 0.684 0.818 11,867
1–
4 12 15.000 19,099 58.000 0.570 0.682 14,061
6 Parallel Bars
1– 1
4
–
2 0.750 955 2.898 11.398 13.637 1,061
1– –3
4 4 1.125 1,432 4.356 7.587 9.078 1,415
1–
4 1 1.500 1,910 5.796 5.698 6.818 1,778
1–
4 11–2 2.250 2,865 8.700 3.793 4.538 2,501
1–
4 2 3.000 3,820 11.580 2.858 3.420 3,186
1–
4 21–2 3.750 4,775 14.460 2.287 2.735 3,851
1–
4 3 4.500 5,730 17.400 1.905 2.280 4,527
1–
4 31–2 5.250 6,685 20.280 1.628 1.948 5,307
1–
4 4 6.000 7,639 23.160 1.425 1.705 5,821
1–
4 5 7.500 9,549 28.980 1.140 1.363 7,108
1–
4 6 9.000 11,459 34.800 0.952 1.138 8,364
1–
4 8 12.000 15,279 46.380 0.712 0.852 10,980
1–
4 10 15.000 19,099 57.960 0.570 0.682 13,388
1–
4 12 18.000 22,918 69.600 0.475 0.568 15,863
7 Parallel Bars
1– 1
4
–
2 0.875 1,114 3.381 9.770 11.689 1,206
1– –3
4 4 1.313 1,671 5.082 6.503 7.781 1,608
1–
4 1 1.750 2,228 6.762 4.884 5.844 2,020
1–
4 11–2 2.625 3,342 10.150 3.251 3.890 2,842
1–
4 2 3.500 4,456 13.510 2.450 2.931 3,620
1–
4 21–2 4.375 5,570 16.870 1.960 2.344 4,376
1–
4 3 5.250 6,685 20.300 1.633 1.954 5,144
1–
4 31–2 6.125 7,799 23.660 1.396 1.670 6,031
1–
4 4 7.000 8,913 27.020 1.221 1.461 6,614
1–
4 5 8.750 11,141 33.810 0.977 1.169 8,078
1–
4 6 10.500 13,369 40.600 0.816 0.976 9,505
1–
4 8 14.000 17,825 54.110 0.610 0.730 12,477
1–
4 10 17.500 22,282 67.620 0.489 0.584 15,214
1–
4 12 21.000 26,738 81.200 0.407 0.487 18,027
(continued)
280 SYSTEM DESIGN

Table 5.18(a) Rigid Copper Busbar Properties—1–4-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) /ft /ft (A)
8 Parallel Bars
1– 1
4
–
2 1.000 1,273 3.864 8.549 10.228 1,327
1– –3
4 4 1.500 1,910 5.808 5.690 6.809 1,769
1–
4 1 2.000 2,546 7.728 4.274 5.114 2,222
1–
4 11–2 3.000 3,820 11.600 2.845 3.404 3,126
1–
4 2 4.000 5,093 15.440 2.144 2.565 3,982
1–
4 21–2 5.000 6,366 19.280 1.715 2.051 4,813
1–
4 3 6.000 7,639 23.200 1.429 1.710 5,659
1–
4 31–2 7.000 8,913 27.040 1.221 1.461 6,634
1–
4 4 8.000 10,186 30.880 1.069 1.279 7,276
1–
4 5 10.000 12,732 38.640 0.855 1.023 8,886
1–
4 6 12.000 15,279 46.400 0.714 0.854 10,455
1–
4 8 16.000 20,372 61.840 0.534 0.639 13,725
1–
4 10 20.000 25,465 77.280 0.428 0.511 16,735
1–
4 12 24.000 30,558 92.800 0.356 0.426 19,829
9 Parallel Bars
1– 1
4
–
2 1.125 1,432 4.347 7.599 9.091 1,447
1– –3
4 4 1.688 2,149 6.534 5.058 6.052 1,930
1–
1 4 2.250 2,865 8.694 3.799 4.546 2,424
1–
11–24 3.375 4,297 13.050 2.529 3.026 3,410
1–
2 4 4.500 5,730 17.370 1.906 2.280 4,344
1–
21–24 5.625 7,162 21.690 1.524 1.823 5,251
1–
3 4 6.750 8,594 26.100 1.270 1.520 6,173
1–
31–24 7.875 10,027 30.420 1.086 1.299 7,237
1–
4 4 9.000 11,459 34.740 0.950 1.137 7,937
1–
5 4 11.250 14,324 43.470 0.760 0.909 9,693
1–
6 4 13.500 17,189 52.200 0.634 0.759 11,406
1–
8 4 18.000 22,918 69.570 0.474 0.568 14,972
1–
10 4 22.500 28,648 86.940 0.380 0.454 18,256
1–
12 4 27.000 34,377 104.400 0.317 0.379 21,632
10 Parallel Bars
1– 1
4
–
2 1.250 1,592 4.830 6.839 8.182 1,568
1– –3
4 4 1.875 2,387 7.260 4.552 5.447 2,090
1–
4 1 2.500 3,183 9.660 3.419 4.091 2,626
1–
4 11–2 3.750 4,775 14.500 2.276 2.723 3,694
1–
4 2 5.000 6,366 19.300 1.715 2.052 4,706
1–
4 21–2 6.250 7,958 24.100 1.372 1.641 5,688
1–
4 3 7.500 9,549 29.000 1.143 1.368 6,687
1–
4 31–2 8.750 11,141 33.800 0.977 1.169 7,840
1–
4 4 10.000 12,732 38.600 0.855 1.023 8,599
1–
4 5 12.500 15,915 48.300 0.684 0.818 10,501
1–
4 6 15.000 19,099 58.000 0.571 0.683 12,356
1–
4 8 20.000 25,465 77.300 0.427 0.511 16,220
1–
4 10 25.000 31,831 96.600 0.342 0.409 19,778
1–
4 12 30.000 38,197 116.000 0.285 0.341 23,435
 5.8 CIRCUIT DESIGN 281

Table 5.18(a) Rigid Copper Busbar Properties—1–4-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) /ft /ft (A)
11 Parallel Bars
1– 1
4
–
2 1.375 1,751 5.313 6.217 7.438 1,664
1– –3
4 4 2.063 2,626 7.986 4.138 4.952 2,219
1–
1 4 2.750 3,501 10.626 3.108 3.719 2,787
1–
11–24 4.125 5,252 15.950 2.069 2.475 3,922
1–
2 4 5.500 7,003 21.230 1.559 1.865 4,996
1–
21–24 6.875 8,754 26.510 1.247 1.492 6,038
1–
3 4 8.250 10,504 31.900 1.039 1.244 7,099
1–
31–24 9.625 12,255 37.180 0.888 1.063 8,322
1–
4 4 11.000 14,006 42.460 0.777 0.930 9,128
1–
5 4 13.750 17,507 53.130 0.622 0.744 11,147
1–
6 4 16.500 21,008 63.800 0.519 0.621 13,117
1–
8 4 22.000 28,011 85.030 0.388 0.465 17,218
1–
10 4 27.500 35,014 106.260 0.311 0.372 20,995
1–
12 4 33.000 42,017 127.600 0.259 0.310 24,877
12 Parallel Bars
1– 1
4
–
2 1.500 1,910 5.796 5.699 6.818 1,761
1– –3
4 4 2.250 2,865 8.712 3.793 4.539 2,348
1–
4 1 3.000 3,820 11.592 2.849 3.409 2,949
1–
4 11–2 4.500 5,730 17.400 1.897 2.269 4,149
1–
4 2 6.000 7,639 23.160 1.429 1.710 5,286
1–
4 21–2 7.500 9,549 28.920 1.143 1.368 6,388
1–
4 3 9.000 11,459 34.800 0.953 1.140 7,511
1–
4 31–2 10.500 13,369 40.560 0.814 0.974 8,805
1–
4 4 12.000 15,279 46.320 0.713 0.853 9,657
1–
4 5 15.000 19,099 57.960 0.570 0.682 11,794
1–
4 6 18.000 22,918 69.600 0.476 0.569 13,877
1–
4 8 24.000 30,558 92.760 0.356 0.426 18,216
1–
4 10 30.000 38,197 115.920 0.285 0.341 22,212
1–
4 12 36.000 45,837 139.200 0.238 0.284 26,319
a
1 /ft = 1 × 10–6 /ft. For example, 68.39 /ft = 68.39 × 10–6 /ft.
b
Current ratings apply when the busbar is oriented with its long edge vertical, and bar spacing bar thickness,
and busbar is run in the horizontal plane. Current ratings based on 30°C rise above 40°C ambient temperature.
Source: Data from www.copper.org (Copper Development Association, Inc.) with adjustments.

K factor) to arrive at the circular mil area required to keep voltage drop below some
specified threshold at a given temperature.
앫 The second method is based on a conventional application of Ohm’s law.

Both methods yield equivalent results, and both methods require knowledge of the con-
ductor length as determined from the conductor path distance. The path distance is the
one-way distance from termination to termination, including vertical and horizontal runs,
as shown in Figure 5.35. Since dc power conductors always are installed in a paired
282 SYSTEM DESIGN

Table 5.18(b) Rigid Copper Busbar Properties—38–-in. Parallel Bars as Indicateda,b

DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
2 Parallel Bars
3– –3
8 4 0.5625 716 2.18 15.225 18.220 754
3–
8 1 0.750 955 2.90 11.380 13.615 932
3–
8 11–2 1.125 1,432 4.34 7.585 9.080 1,310
3–
8 2 1.500 1,910 5.80 5.715 6.840 1,646
3–
8 21–2 1.875 2,387 7.24 4.555 5.455 2,000
3–
8 3 2.250 2,865 8.70 3.820 4.570 2,316
3–
8 31–2 2.625 3,342 10.12 3.265 3.905 2,640
3–
8 4 3.000 3,820 11.60 2.855 3.415 2,958
3–
8 5 3.750 4,775 14.52 2.275 2.725 3,608
3–
8 6 4.500 5,730 17.38 1.900 2.275 4,260
3–
88 6.000 7,639 23.20 1.425 1.705 5,501
3–
10
8 7.500 9,549 29.00 1.140 1.360 6,766
3–
128 9.000 11,459 34.80 0.950 1.140 7,936
3 Parallel Bars
3– –3
8 4 0.844 1,074 3.27 10.150 12.147 1,048
3–
8 1 1.125 1,432 4.35 7.587 9.077 1,294
3–
8 11–2 1.688 2,149 6.51 5.057 6.053 1,819
3–
8 2 2.250 2,865 8.70 3.810 4.560 2,286
3–
8 21–2 2.813 3,581 10.86 3.037 3.637 2,778
3–
8 3 3.375 4,297 13.05 2.547 3.047 3,217
3–
8 31–2 3.938 5,013 15.18 2.177 2.603 3,666
3–
8 4 4.500 5,730 17.40 1.903 2.277 4,108
3–
8 5 5.625 7,162 21.78 1.517 1.817 5,011
3–
8 6 6.750 8,594 26.07 1.267 1.517 5,916
3–
88 9.000 11,459 34.80 0.950 1.137 7,640
3–
10
8 11.250 14,324 43.50 0.760 0.907 9,398
3–
128 13.500 17,189 52.20 0.633 0.760 11,023
4 Parallel Bars
3– –3
8 4 1.125 1,432 4.36 7.613 9.110 1,341
3–
8 1 1.500 1,910 5.80 5.690 6.808 1,656
3–
8 11–2 2.250 2,865 8.68 3.793 4.540 2,328
3–
8 2 3.000 3,820 11.60 2.858 3.420 2,926
3–
8 21–2 3.750 4,775 14.48 2.278 2.728 3,556
3–
8 3 4.500 5,730 17.40 1.910 2.285 4,118
3–
8 31–2 5.250 6,685 20.24 1.633 1.953 4,693
3–
8 4 6.000 7,639 23.20 1.428 1.708 5,258
3–
8 5 7.500 9,549 29.04 1.138 1.363 6,414
3–
8 6 9.000 11,459 34.76 0.950 1.138 7,573
3–
88 12.000 15,279 46.40 0.713 0.853 9,780
3–
10
8 15.000 19,099 58.00 0.570 0.680 12,029
3–
128 18.000 22,918 69.60 0.475 0.570 14,109
5 Parallel Bars
3– –3
8 4 1.406 1,790 5.45 6.090 7.288 1,635
3–
8 1 1.875 2,387 7.25 4.552 5.446 2,019
3–
8 11–2 2.813 3,581 10.85 3.034 3.632 2,837
 5.8 CIRCUIT DESIGN 283

Table 5.18(b) Rigid Copper Busbar Properties—3–8-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
5 Parallel Bars
3–
8 2 3.750 4,775 14.50 2.286 2.736 3,567
3–
8 21–2 4.688 5,968 18.10 1.822 2.182 4,334
3–
8 3 5.625 7,162 21.75 1.528 1.828 5,019
3–
8 31–2 6.563 8,356 25.30 1.306 1.562 5,719
3–
8 4 7.500 9,549 29.00 1.142 1.366 6,408
3–
8 5 9.375 11,937 36.30 0.910 1.090 7,817
3–
8 6 11.250 14,324 43.45 0.760 0.910 9,230
3–
8 8 15.000 19,099 58.00 0.570 0.682 11,919
3–
8 10 18.750 23,873 72.50 0.456 0.544 14,661
3–
8 12 22.500 28,648 87.00 0.380 0.456 17,195
6 Parallel Bars
3– –3
8 4 1.688 2,149 6.54 5.075 6.073 1,844
3–
8 1 2.250 2,865 8.70 3.793 4.538 2,277
3–
8 11–2 3.375 4,297 13.02 2.528 3.027 3,201
3–
8 2 4.500 5,730 17.40 1.905 2.280 4,024
3–
8 21–2 5.625 7,162 21.72 1.518 1.818 4,889
3–
8 3 6.750 8,594 26.10 1.273 1.523 5,662
3–
8 31–2 7.875 10,027 30.36 1.088 1.302 6,452
3–
8 4 9.000 11,459 34.80 0.952 1.138 7,230
3–
8 5 11.250 14,324 43.56 0.758 0.908 8,819
3–
86 13.500 17,189 52.14 0.633 0.758 10,413
3–
8
8 18.000 22,918 69.60 0.475 0.568 13,447
3–
108 22.500 28,648 87.00 0.380 0.453 16,540
3–
12 8 27.000 34,377 104.40 0.317 0.380 19,400
7 Parallel Bars
3– –3
8 4 1.969 2,507 7.63 4.350 5.206 2,096
3–
8 1 2.625 3,342 10.15 3.251 3.890 2,588
3–
8 11–2 3.938 5,013 15.19 2.167 2.594 3,638
3–
8 2 5.250 6,685 20.30 1.633 1.954 4,573
3–
8 21–2 6.563 8,356 25.34 1.301 1.559 5,556
3–
8 3 7.875 10,027 30.45 1.091 1.306 6,434
3–
8 31–2 9.188 11,698 35.42 0.933 1.116 7,332
3–
8 4 10.500 13,369 40.60 0.816 0.976 8,216
3–
8 5 13.125 16,711 50.82 0.650 0.779 10,022
3–
86 15.750 20,054 60.83 0.543 0.650 11,833
3–
8
8 21.000 26,738 81.20 0.407 0.487 15,281
3–
108 26.250 33,423 101.50 0.326 0.389 18,796
3–
12 8 31.500 40,107 121.80 0.271 0.326 22,045
8 Parallel Bars
3– –3
8 4 2.250 2,865 8.72 3.806 4.555 2,305
3–
8 1 3.000 3,820 11.60 2.845 3.404 2,847
3–
8 11–2 4.500 5,730 17.36 1.896 2.270 4,001
3–
8 2 6.000 7,639 23.20 1.429 1.710 5,030
3–
8 21–2 7.500 9,549 28.96 1.139 1.364 6,112
3–
8 3 9.000 11,459 34.80 0.955 1.143 7,078
(continued)
284 SYSTEM DESIGN

Table 5.18(b) Rigid Copper Busbar Properties—3–8-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
8 Parallel Bars
3–
8 31–2 10.500 13,369 40.48 0.816 0.976 8,066
3–
8 4 12.000 15,279 46.40 0.714 0.854 9,037
3–
8 5 15.000 19,099 58.08 0.569 0.681 11,024
3–
8 6 18.000 22,918 69.52 0.475 0.569 13,016
3–
8 8 24.000 30,558 92.80 0.356 0.426 16,809
3–
8 10 30.000 38,197 116.00 0.285 0.340 20,675
3–
8 12 36.000 45,837 139.20 0.238 0.285 24,250
9 Parallel Bars
3– –3
8 4 2.531 3,223 9.81 3.383 4.049 2,515
3–
8 1 3.375 4,297 13.05 2.529 3.026 3,106
3–
8 11–2 5.063 6,446 19.53 1.686 2.018 4,365
3–
8 2 6.750 8,594 26.10 1.270 1.520 5,487
3–
8 21–2 8.438 10,743 32.58 1.012 1.212 6,667
3–
8 3 10.125 12,892 39.15 0.849 1.016 7,721
3–
8 31–2 11.813 15,040 45.54 0.726 0.868 8,799
3–
84 13.500 17,189 52.20 0.634 0.759 9,859
3–
5
8 16.875 21,486 65.34 0.506 0.606 12,026
3–
68 20.250 25,783 78.21 0.422 0.506 14,199
3–
8 8 27.000 34,377 104.40 0.317 0.379 18,337
3–
10 8 33.750 42,972 130.50 0.253 0.302 22,555
3–
12 8 40.500 51,566 156.60 0.211 0.253 26,454
10 Parallel Bars
3– –3
8 4 2.813 3,581 10.90 3.045 3.644 2,724
3–
8 1 3.750 4,775 14.50 2.276 2.723 3,364
3–
8 11–2 5.625 7,162 21.70 1.517 1.816 4,729
3–
8 2 7.500 9,549 29.00 1.143 1.368 5,944
3–
8 21–2 9.375 11,937 36.20 0.911 1.091 7,223
3–
8 3 11.250 14,324 43.50 0.764 0.914 8,365
3–
8 31–2 13.125 16,711 50.60 0.653 0.781 9,532
3–
84 15.000 19,099 58.00 0.571 0.683 10,681
3–
5
8 18.750 23,873 72.60 0.455 0.545 13,029
3–
68 22.500 28,648 86.90 0.380 0.455 15,383
3–
8 8 30.000 38,197 116.00 0.285 0.341 19,865
3–
10 8 37.500 47,746 145.00 0.228 0.272 24,434
3–
12 8 45.000 57,296 174.00 0.190 0.228 28,659
11 Parallel Bars
3– –3
8 4 3.094 3,939 11.99 2.768 3.313 2,892
3–
8 1 4.125 5,252 15.95 2.069 2.475 3,571
3–
8 11–2 6.188 7,878 23.87 1.379 1.651 5,020
3–
8 2 8.250 10,504 31.90 1.039 1.244 6,310
3–
8 21–2 10.313 13,130 39.82 0.828 0.992 7,667
3–
8 3 12.375 15,756 47.85 0.695 0.831 8,879
3–
8 31–2 14.438 18,382 55.66 0.594 0.710 10,119
3–
8 4 16.500 21,008 63.80 0.519 0.621 11,338
3–
8 5 20.625 26,261 79.86 0.414 0.495 13,830
 5.8 CIRCUIT DESIGN 285

Table 5.18(b) Rigid Copper Busbar Properties—1–2-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
11 Parallel Bars
3–
8 6 24.750 31,513 95.59 0.345 0.414 16,329
3–
8 8 33.000 42,017 127.60 0.259 0.310 21,087
3–
8 10 41.250 52,521 159.50 0.207 0.247 25,938
3–
8 12 49.500 63,025 191.40 0.173 0.207 30,423
12 Parallel Bars
3– –3
8 4 3.375 4,297 13.08 2.538 3.037 3,060
3–
8 1 4.500 5,730 17.40 1.897 2.269 3,778
3–
8 11–2 6.750 8,594 26.04 1.264 1.513 5,311
3–
8 2 9.000 11,459 34.80 0.953 1.140 6,676
3–
8 21–2 11.250 14,324 43.44 0.759 0.909 8,112
3–
8 3 13.500 17,189 52.20 0.637 0.762 9,394
3–
8 31–2 15.750 20,054 60.72 0.544 0.651 10,705
3–
8 4 18.000 22,918 69.60 0.476 0.569 11,995
3–
8 5 22.500 28,648 87.12 0.379 0.454 14,632
3–
8 6 27.000 34,377 104.28 0.317 0.379 17,276
3–
8 8 36.000 45,837 139.20 0.238 0.284 22,310
3–
8 10 45.000 57,296 174.00 0.190 0.227 27,442
3–
8 12 54.000 68,755 208.80 0.158 0.190 32,186
a
1 /ft = 1 × 10–6 /ft. For example, 68.39 /ft = 68.39 × 10–6 /ft.
b
Current ratings apply when the busbar is oriented with its long edge vertical, and bar spacing bar thickness,
and busbar is run in the horizontal plane. Current ratings based on 30°C rise above 40°C ambient temperature.
Source: Data from www.copper.org (Copper Development Association, Inc.) with adjustments.

Table 5.18(c) Rigid Copper Busbar Properties—1–2-in. Parallel Bars as Indicateda,b

DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
2 Parallel Bars
1–
2 1 1.000 1,273 3.860 8.575 10.260 1,138
1–
2 11–2 1.500 1,910 5.800 5.715 6.840 1,553
1–
2 2 2.000 2,546 7.720 4.275 5.115 1,905
1–
2 21–2 2.500 3,183 9.660 3.420 4.090 2,326
1–
2 3 3.000 3,820 11.600 2.855 3.415 2,761
1–
2 31–2 3.500 4,456 13.520 2.440 2.920 3,107
1–
2 4 4.000 5,093 15.460 2.135 2.555 3,435
1–
2 5 5.000 6,366 19.320 1.710 2.045 4,239
1–
2 6 6.000 7,639 23.200 1.425 1.705 5,038
1–
2 8 8.000 10,186 31.000 1.070 1.280 6,435
1–
2 10 10.000 12,732 38.600 0.855 1.025 7,857
1–
2 12 12.000 15,279 46.400 0.710 0.850 9,321
(continued)
286 SYSTEM DESIGN

Table 5.18(c) Rigid Copper Busbar Properties—1–2-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
3 Parallel Bars
1–
2 1 1.500 1,910 5.790 5.717 6.840 1,581
1–
2 11–2 2.250 2,865 8.700 3.810 4.560 2,156
1–
2 2 3.000 3,820 11.580 2.850 3.410 2,646
1–
2 21–2 3.750 4,775 14.490 2.280 2.727 3,231
1–
2 3 4.500 5,730 17.400 1.903 2.277 3,834
1–
2 31–2 5.250 6,685 20.280 1.627 1.947 4,315
1–
2 4 6.000 7,639 23.190 1.423 1.703 4,771
1–
2 5 7.500 9,549 28.980 1.140 1.363 5,888
1–
2 6 9.000 11,459 34.800 0.950 1.137 6,997
1–
2 8 12.000 15,279 46.500 0.713 0.853 8,937
1–
2 10 15.000 19,099 57.900 0.570 0.683 10,912
1–
2 12 18.000 22,918 69.600 0.473 0.567 12,945
4 Parallel Bars
1–
2 1 2.000 2,546 7.720 4.288 5.130 2,023
1–
2 11–2 3.000 3,820 11.600 2.858 3.420 2,760
1–
2 2 4.000 5,093 15.440 2.138 2.558 3,387
1–
2 21–2 5.000 6,366 19.320 1.710 2.045 4,136
1–
2 3 6.000 7,639 23.200 1.428 1.708 4,908
1–
2 31–2 7.000 8,913 27.040 1.220 1.460 5,523
1–
2 4 8.000 10,186 30.920 1.068 1.278 6,106
1–
2 5 10.000 12,732 38.640 0.855 1.023 7,537
1–
2 6 12.000 15,279 46.400 0.713 0.853 8,956
1–
2 8 16.000 20,372 62.000 0.535 0.640 11,440
1–
2 10 20.000 25,465 77.200 0.428 0.513 13,967
1–
2 12 24.000 30,558 92.800 0.355 0.425 16,570
5 Parallel Bars
1–
2 1 2.500 3,183 9.650 3.430 4.104 2,466
1–
2 11–2 3.750 4,775 14.500 2.286 2.736 3,364
1–
2 2 5.000 6,366 19.300 1.710 2.046 4,127
1–
2 21–2 6.250 7,958 24.150 1.368 1.636 5,041
1–
2 3 7.500 9,549 29.000 1.142 1.366 5,981
1–
2 31–2 8.750 11,141 33.800 0.976 1.168 6,731
1–
2 4 10.000 12,732 38.650 0.854 1.022 7,442
1–
2 5 12.500 15,915 48.300 0.684 0.818 9,186
1–
2 6 15.000 19,099 58.000 0.570 0.682 10,916
1–
2 8 20.000 25,465 77.500 0.428 0.512 13,942
1–
2 10 25.000 31,831 96.500 0.342 0.410 17,023
1–
2 12 30.000 38,197 116.000 0.284 0.340 20,195
6 Parallel Bars
1–
2 1 3.000 3,820 11.580 2.858 3.420 2,782
1–
2 11–2 4.500 5,730 17.400 1.905 2.280 3,795
1–
2 2 6.000 7,639 23.160 1.425 1.705 4,657
1–
2 21–2 7.500 9,549 28.980 1.140 1.363 5,687
1–
2 3 9.000 11,459 34.800 0.952 1.138 6,748
1–
2 31–2 10.500 13,369 40.560 0.813 0.973 7,594
 5.8 CIRCUIT DESIGN 287

Table 5.18(c) Rigid Copper Busbar Properties—1–2-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
6 Parallel Bars
1–
2 4 12.000 15,279 46.380 0.712 0.852 8,396
1–
2 5 15.000 19,099 57.960 0.570 0.682 10,363
1–
2 6 18.000 22,918 69.600 0.475 0.568 12,315
1–
2 8 24.000 30,558 93.000 0.357 0.427 15,730
1–
2 10 30.000 38,197 115.800 0.285 0.342 19,205
1–
2 12 36.000 45,837 139.200 0.237 0.283 22,784
7 Parallel Bars
1–
2 1 3.500 4,456 13.510 2.450 2.931 3,161
1–
2 11–2 5.250 6,685 20.300 1.633 1.954 4,313
1–
2 2 7.000 8,913 27.020 1.221 1.461 5,292
1–
2 21–2 8.750 11,141 33.810 0.977 1.169 6,462
1–
2 3 10.500 13,369 40.600 0.816 0.976 7,668
1–
2 31–2 12.250 15,597 47.320 0.697 0.834 8,630
1–
2 4 14.000 17,825 54.110 0.610 0.730 9,541
1–
2 5 17.500 22,282 67.620 0.489 0.584 11,776
1–
2 6 21.000 26,738 81.200 0.407 0.487 13,994
1–
2 8 28.000 35,651 108.500 0.306 0.366 17,875
1–
2 10 35.000 44,563 135.100 0.244 0.293 21,824
1–
2 12 42.000 53,476 162.400 0.203 0.243 25,891
8 Parallel Bars
1–
2 1 4.000 5,093 15.440 2.144 2.565 3,478
1–
2 11–2 6.000 7,639 23.200 1.429 1.710 4,744
1–
2 2 8.000 10,186 30.880 1.069 1.279 5,821
1–
2 21–2 10.000 12,732 38.640 0.855 1.023 7,108
1–
2 3 12.000 15,279 46.400 0.714 0.854 8,435
1–
2 31–2 14.000 17,825 54.080 0.610 0.730 9,493
1–
2 4 16.000 20,372 61.840 0.534 0.639 10,495
1–
2 5 20.000 25,465 77.280 0.428 0.511 12,954
1–
2 6 24.000 30,558 92.800 0.356 0.426 15,394
1–
2 8 32.000 40,744 124.000 0.268 0.320 19,662
1–
2 10 40.000 50,930 154.400 0.214 0.256 24,006
1–
2 12 48.000 61,115 185.600 0.178 0.213 28,480
9 Parallel Bars
1–
2 1 4.500 5,730 17.370 1.906 2.280 3,794
1–
2 11–2 6.750 8,594 26.100 1.270 1.520 5,175
1–
2 2 9.000 11,459 34.740 0.950 1.137 6,350
1–
2 21–2 11.250 14,324 43.470 0.760 0.909 7,755
1–
2 3 13.500 17,189 52.200 0.634 0.759 9,202
1–
2 31–2 15.750 20,054 60.840 0.542 0.649 10,356
1–
2 4 18.000 22,918 69.570 0.474 0.568 11,449
1–
2 5 22.500 28,648 86.940 0.380 0.454 14,132
1–
2 6 27.000 34,377 104.400 0.317 0.379 16,793
1–
2 8 36.000 45,837 139.500 0.238 0.284 21,449
1–
2 10 45.000 57,296 173.700 0.190 0.228 26,189
1–
2 12 54.000 68,755 208.800 0.158 0.189 31,069
(continued)
288 SYSTEM DESIGN

Table 5.18(c) Rigid Copper Busbar Properties—1–2-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
10 Parallel Bars
1–
2 1 5.000 6,366 19.300 1.715 2.052 4,110
1–
2 11–2 7.500 9,549 29.000 1.143 1.368 5,607
1–
2 2 10.000 12,732 38.600 0.855 1.023 6,879
1–
2 21–2 12.500 15,915 48.300 0.684 0.818 8,401
1–
2 3 15.000 19,099 58.000 0.571 0.683 9,969
1–
2 31–2 17.500 22,282 67.600 0.488 0.584 11,219
1–
2 4 20.000 25,465 77.300 0.427 0.511 12,404
1–
2 5 25.000 31,831 96.600 0.342 0.409 15,309
1–
2 6 30.000 38,197 116.000 0.285 0.341 18,193
1–
2 8 40.000 50,930 155.000 0.214 0.256 23,237
1–
2 10 50.000 63,662 193.000 0.171 0.205 28,371
1–
2 12 60.000 76,394 232.000 0.142 0.170 33,658
11 Parallel Bars
1–
2 1 5.500 7,003 21.230 1.559 1.865 4,363
1–
2 11–2 8.250 10,504 31.900 1.039 1.244 5,952
1–
2 2 11.000 14,006 42.460 0.777 0.930 7,302
1–
2 21–2 13.750 17,507 53.130 0.622 0.744 8,918
1–
2 3 16.500 21,008 63.800 0.519 0.621 10,582
1–
2 31–2 19.250 24,510 74.360 0.444 0.531 11,909
1–
2 4 22.000 28,011 85.030 0.388 0.465 13,167
1–
2 5 27.500 35,014 106.260 0.311 0.372 16,251
1–
2 6 33.000 42,017 127.600 0.259 0.310 19,312
1–
2 8 44.000 56,023 170.500 0.195 0.233 24,667
1–
2 10 55.000 70,028 212.300 0.155 0.186 30,117
1–
2 12 66.000 84,034 255.200 0.129 0.155 35,729
12 Parallel Bars
1–
2 1 6.000 7,639 23.160 1.429 1.710 4,616
1–
2 11–2 9.000 11,459 34.800 0.953 1.140 6,297
1–
2 2 12.000 15,279 46.320 0.713 0.853 7,726
1–
2 21–2 15.000 19,099 57.960 0.570 0.682 9,435
1–
2 3 18.000 22,918 69.600 0.476 0.569 11,195
1–
2 31–2 21.000 26,738 81.120 0.407 0.487 12,600
1–
2 4 24.000 30,558 92.760 0.356 0.426 13,930
1–
2 5 30.000 38,197 115.920 0.285 0.341 17,193
1–
2 6 36.000 45,837 139.200 0.238 0.284 20,432
1–
2 8 48.000 61,115 186.000 0.178 0.213 26,097
1–
2 10 60.000 76,394 231.600 0.143 0.171 31,863
1–
2 12 72.000 91,673 278.400 0.118 0.142 37,800
a
1 /ft = 1 × 10–6 /ft. For example, 68.39 /ft = 68.39 × 10–6 /ft.
b
Current ratings apply when the busbar is oriented with its long edge vertical, and bar spacing bar thick-
ness, and busbar is run in the horizontal plane. Current ratings based on 30°C rise above 40°C ambient tem-
perature.
Source: Data from www.copper.org (Copper Development Association, Inc.) with adjustments.
 5.8 CIRCUIT DESIGN 289

Table 5.18(d) Rigid Copper Busbar Properties—3–4-in. Parallel Bars as Indicateda,b

DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
2 Parallel Bars
–3 4 6.00 7,639 23.2 1.425 1.705 4,397
4
–3 5 7.50 9,549 29.0 1.140 1.360 5,256
4
–3 6 9.00 11,459 34.8 0.950 1.140 6,214
4
–3 8 12.00 15,279 46.4 0.710 0.850 7,969
4
–3 10 15.00 19,099 58.0 0.570 0.685 9,770
4
–3 12 18.00 22,918 69.6 0.475 0.570 11,567
4
3 Parallel Bars
–3 4 9.00 11,459 34.8 0.950 1.137 6,107
4
–3 5 11.25 14,324 43.5 0.760 0.907 7,299
4
–3 6 13.50 17,189 52.2 0.633 0.760 8,630
4
–3 8 18.00 22,918 69.6 0.473 0.567 11,068
4
–3 10 22.50 28,648 87.0 0.380 0.457 13,569
4
–3 12 27.00 34,377 104.4 0.317 0.380 16,066
4
4 Parallel Bars
–3 4 12.00 15,279 46.4 0.713 0.853 7,817
4
–3 5 15.00 19,099 58.0 0.570 0.680 9,343
4
–3 6 18.00 22,918 69.6 0.475 0.570 11,047
4
–3 8 24.00 30,558 92.8 0.355 0.425 14,167
4
–3 10 30.00 38,197 116.0 0.285 0.343 17,368
4
–3 12 36.00 45,837 139.2 0.238 0.285 20,564
4
5 Parallel Bars
–3 4 15.00 19,099 58.0 0.570 0.682 9,527
4
–3 5 18.75 23,873 72.5 0.456 0.544 11,387
4
–3 6 22.5 28,648 87.0 0.380 0.456 13,463
4
–3 8 30.0 38,197 116.0 0.284 0.340 17,266
4
–3 10 37.5 47,746 145.0 0.228 0.274 21,168
4
–3 12 45.0 57,296 174.0 0.190 0.228 25,063
4
6 Parallel Bars
–3 4 18.0 22,918 69.6 0.475 0.568 10,749
4
–3 5 22.5 28,648 87.0 0.380 0.453 12,847
4
–3 6 27.0 34,377 104.4 0.317 0.380 15,189
4
–3 8 36.0 45,837 139.2 0.237 0.283 19,480
4
–3 10 45.0 57,296 174.0 0.190 0.228 23,881
4
–3 12 54.0 68,755 208.8 0.158 0.190 28,276
4
7 Parallel Bars
–3 4 21.0 26,738 81.2 0.407 0.487 12,214
4
–3 5 26.2 33,423 101.5 0.326 0.389 14,599
4
–3 6 31.5 40,107 121.8 0.271 0.326 17,260
4
–3 8 42.0 53,476 162.4 0.203 0.243 22,136
4
–3 10 52.5 66,845 203.0 0.163 0.196 27,138
4
–3 12 63.0 80,214 243.6 0.136 0.163 32,131
4
8 Parallel Bars
–3 4 24.0 30,558 92.8 0.356 0.426 13,436
4
–3 5 30.0 38,197 116.0 0.285 0.340 16,058
4
–3 6 36.0 45,837 139.2 0.238 0.285 18,986
4
(continued)
290 SYSTEM DESIGN

Table 5.18(d) Rigid Copper Busbar Properties—3–4-in. Parallel Bars as Indicateda,b (Continued)
DC Current
Dimensions DC Resistance Rating
_____________________________________ __________________ ________
Thickness Width Area Weight 30°C 70°C 70°C
(in.) (in.) (in.2) (kcmil) (lb/ft) (/ft) (/ft) (A)
8 Parallel Bars
–3 8 48.0 61,115 185.6 0.178 0.213 24,350
4
–3 10 60.0 76,394 232.0 0.143 0.171 29,852
4
–3 12 72.0 91,673 278.4 0.119 0.143 35,345
4
9 Parallel Bars
–3 4 27.0 34,377 104.4 0.317 0.379 14,657
4
–3 5 33.7 42,972 130.5 0.253 0.302 17,518
4
–3 6 40.5 51,566 156.6 0.211 0.253 20,712
4
–3 8 54.0 68,755 208.8 0.158 0.189 26,563
4
–3 10 67.5 85,944 261.0 0.127 0.152 32,566
4
–3 12 81.0 103,132 313.2 0.106 0.127 38,558
4
10 Parallel Bars
–3 4 30.0 38,197 116.0 0.285 0.341 15,879
4
–3 5 37.5 47,746 145.0 0.228 0.272 18,978
4
–3 6 45.0 57,296 174.0 0.190 0.228 22,438
4
–3 8 60.0 76,394 232.0 0.142 0.170 28,777
4
–3 10 75.0 95,493 290.0 0.114 0.137 35,279
4
–3 12 90.0 114,592 348.0 0.095 0.114 41,771
4
11 Parallel Bars
–3 4 33.0 42,017 127.6 0.259 0.310 16,856
4
–3 5 41.2 52,521 159.5 0.207 0.247 20,146
4
–3 6 49.5 63,025 191.4 0.173 0.207 23,819
4
–3 8 66.0 84,034 255.2 0.129 0.155 30,548
4
–3 10 82.5 105,042 319.0 0.104 0.125 37,450
4
–3 12 99.0 126,051 382.8 0.086 0.104 44,341
4
12 Parallel Bars
–3 4 36.0 45,837 139.2 0.238 0.284 17,833
4
–3 5 45.0 57,296 174.0 0.190 0.227 21,314
4
–3 6 54.0 68,755 208.8 0.158 0.190 25,200
4
–3 8 72.0 91,673 278.4 0.118 0.142 32,318
4
–3 10 90.0 114,592 348.0 0.095 0.114 39,621
4
–3 12 108.0 137,510 417.6 0.079 0.095 46,912
4
a
1 /ft = 1 × 10–6 /ft. For example, 68.39 /ft = 68.39 × 10–6 /ft.
b
Current ratings apply when the busbar is oriented with its long edge vertical, and bar spacing bar thickness,
and busbar is run in the horizontal plane. Current ratings based on 30°C rise above 40°C ambient temperature.
Source: Data from www.copper.org (Copper Development Association, Inc.) with adjustments.
 5.8 CIRCUIT DESIGN 291

Table 5.19 Alternate Values of DC Current Ratings for Rigid Copper Busbar—1–4-in. and 1–2-in.
Parallel Bars as Indicateda,b,c
DC Current Rating DC Current Rating
__________________ _________________
Dimensions 70°C 70°C Dimensions 70°C 70°C
Thickness Width Vertical Other Thickness Width Vertical Other
(in.) (in.) (A) (A) (in.) (in.) (A) (A)
1 Bar
1– 1
4 2 731 721 –
2 2 1,088 1,073
1– 1
4 3 1,040 1,019 –
2 3 1,525 1,494
1– 1
4 4 1,342 1,296 –
2 4 1,951 1,887
1– 1
4 6 1,931 1,820 –
2 6 2,783 2,623
1– 1
4 8 2,506 2,292 –
2 8 3,596 3,289
2 Parallel Bars
1– 1
4 2 1,301 1,259 –
2 2 1,961 1,902
1– 1
4 3 1,834 1,735 –
2 3 2,715 2,577
1– 1
4 4 2,350 2,163 –
2 4 3,445 3,182
1– 1
4 6 3,352 2,937 –
2 6 4,861 4,275
1– 1
4 8 4,325 3,583 –
2 8 6,236 5,189
3 Parallel Bars
1–
4 2 1,865 1,787 — — — —
1–
4 3 2,616 2,432 — — — —
1– 1
4 4 3,342 2,996 –
2 4 4,918 4,437
1– 1
4 6 4,745 3,992 –
2 6 6,902 5,848
1– 1
4 8 6,105 4,770 –
2 8 8,824 6,950
4 Parallel Bars
1–
4 2 2,426 2,313 — — — —
1–
4 3 3,394 3,123 — — — —
1– 1
4 4 4,328 3,819 –
2 4 6,384 5,673
1– 1
4 6 6,130 5,026 –
2 6 8,933 7,392
1– 1
4 8 7,872 5,916 –
2 8 11,395 8,659
5 Parallel Bars
1– 1
4 4 5,312 4,637 –
2 4 7,847 6,915
1– 1
4 6 7,512 6,048 –
2 6 10,960 8,921
1– 1
4 8 9,634 7,041 –
2 8 13,960 10,340
6 Parallel Bars
1– 1
4 4 6,295 5,452 –
2 4 9,309 8,148
1– 1
4 6 8,891 7,064 –
2 6 12,980 10,445
1– 1
4 8 11,395 8,154 –
2 8 16,520 12,005
7 Parallel Bars
1– 1
4 6 10,270 8,076 –
2 6 15,000 11,960
1– 1
4 8 13,150 9,259 –
2 8 19,080 13,660
8 Parallel Bars
1– 1
4 6 11,645 9,086 –
2 6 17,020 13,475
1– 1
4 8 14,905 10,360 –
2 8 21,635 15,310
9 Parallel Bars
1– 1
4 6 13,020 10,095 –
2 6 19,040 14,985
1– 1
4 8 16,660 11,455 –
2 8 24,190 16,955
10 Parallel Bars
1– 1
4 6 14,400 11,100 –
2 6 21,060 16,495
1– 1
4 8 18,415 12,545 –
2 8 26,745 18,600
(continued)
292 SYSTEM DESIGN

Table 5.19 Alternate Values of DC Current Ratings for Rigid Copper Busbar—1–4-in. and 1–2-in.
Parallel Bars as Indicateda,b,c (Continued)
DC Current Rating DC Current Rating
__________________ _________________
Dimensions 70°C 70°C Dimensions 70°C 70°C
Thickness Width Vertical Other Thickness Width Vertical Other
(in.) (in.) (A) (A) (in.) (in.) (A) (A)
11 Parallel Bars
1–
4 6 15,775 12,105 — — — —
1–
4 8 20,170 13,640 — — — —
12 Parallel Bars
1–
4 6 17,150 13,110 — — — —
1–
4 8 21,925 14,725 — — — —
a
Some current ratings in this table differ slightly from the current ratings given in previous tables. The differ-
ences are due to historic precedent.
b
Current ratings in the “Vertical” column apply when the busbars are oriented with their long edge vertical, and
bar spacing bar thickness, and busbar is run in the horizontal direction.
c
Current ratings in the “Other” column apply with the busbars are oriented with their long edge horizontal, or
when bar spacing < bar thickness, or when the bar is run in the vertical direction.
d
Current ratings based on 30°C rise above 40°C ambient temperature.
Source: Data from [28].

arrangement with a feed and return leads following the same path, the actual conductor
length for a given circuit, or loop length, is twice (2×) the path distance. Because of bus
mechanical arrangements, it is possible the feed and return conductors have slightly dif-
ferent lengths. In this case, the estimated path distance would be two times the average of
the feed and return distances.
As mentioned in Section 5.2.2.2, industry standards suggest no more than 2.0 V total
drop between the battery terminals and load equipment for 48-V systems and 1.0 V for
24-V systems. These voltage drops are not fixed throughout any given system (the volt-
age drop can be less or more in any particular circuit) but are target maximum values that
are used to rationalize circuit design. The target values will be considered specified maxi-
mum values for the purposes of circuit design in this book.
Since the important parameter is the total voltage drop from the battery terminals to the
load equipment terminals, the voltage drop in each segment (battery, primary distribution,
and secondary distribution circuits) can be designed for any value as long as the sum of
the voltage drops does not exceed the maximum.
The voltage drop between the battery terminals and the discharge bus normally is in
the range of 0.25 to 0.75 V for 48-V systems, with 0.5 V being a good starting value for
design purposes (one-half these values for 24-V systems). These values work particularly
well if the battery is near the powerboard discharge bus and the loads are farther away.
Where the situation is reversed, and the battery is far away and the load is near, the bat-
tery circuit usually is designed for a higher voltage drop to reduce conductor size. Since
only the total voltage drop is specified, the designer has flexibility in circuit segment de-
sign. Typical values for each circuit segment are shown in Table 5.20.
For the first voltage drop calculation method
FVD LLoad LLoop
CM =  (5.25)
VDrop